Process of welding



Sept. 11, 1934. w. F. SCHULZ PROCESS OF WELDING Filed May 26. 1932 Patented Sept. 11, 1934 UNITED STATES PATENT OFFICE PROCESS OF WELDING Walter F. Schulz, Youngstown, Ohio, assignor to Truscon Steel Company, Youngstown, Ohio, a corporation of Michigan Application May 26, 1932, Serial No. 613,754 2 Claims. (Cl. 219-40) The present invention relates to a novel process tion of the parts at the beginning of the welding of uniting by electric welding parts that are process. seated to a substantial extent one within the Figure 2 is a similar view showing the relation other, the object being to produce an efficient weld of the parts at the end of the welding process.

throughout the interrelated portions of the parts Figure 3 is a detail perspective view showing 60 so seated. the finished product.

In the process of electrical resistance pressure Figure 4 is a view outlining the effects secured welding of metal parts, a suitable electric curby welding a rectangular bar into a plate. rent of the required voltage and amperage is Figure 5 is a similar view but showing the result caused, by means of suitable connection of the obtained in weldingaround bar intoaplate. 6 means of conducting the electricity, to flow over Referring first to Figure 4, assumingthat the portions of the parts to be welded from points lower surface of a square bar 6 is brought into beyond to and through the proposed point of contact with the upper edge of the plate 7 for the welding. purpose of welding the two together and causing The parts are brought together so as to fully the bar 6 to be embedded in the plate 7, if there complete the electric circuit provided through is initially and thereafter continued sufficient approximately complete continuity of the metal current-and pressure for the successive steps, parts as electric conductors. The lack of abso fusion will occur in the top of the plate '7 and the lutely complete continuity where the parts are bottom of the bar 6 at their line of contact. As

20 brought together sets up resistance to the flow the metals are thus softened and pressure conof current, which resistance develops heat, which tinued, the bar continues to fuse its area into the heat will fuse the metals of the parts at the surarea of the plate. As the bar becomes further faces of most nearly complete contact to the and further embedded in the plate, fusion will extent of the capacity of the current and referable occur along adjacent portions, indicated by the 25 to the concentration of the current in operative horizontal lines at 8, but there will not be suffieffect upon varying areas of approximate concient pressure against or between these portions to tact, all considered with reference to the physical restore the strength of the fused metal or procharacteristics of the metals involved. The initial duce a composite union of approximately the effect of the fusion is to change the structure strength of the original metal. The eflicient weld 30 of the metal in such respects as to weaken its occurs only at the bottom 9 or as indicated by the strength of cohesion after cooling if the current vertical lines, leaving the final structure weakened is withdrawn without the application of presalong the sides 8 of the bar. In the parlance of sure. Pressure applied to the metal while cooling the art, metal fused but not subjected to sulfifrom the fusion temperature to at least below cient pressure to develop efficient welding strength 35 Ac 3 in the critical range, tends to restore such is called burnt metal. Obviously therefore a strength. satisfactorily sufiicient composite real welding union between the parts only occurs union .of the fusedmetals to complete the weld at the bottom of the bar 6. occurs only where sufficient pressure is applied Much the same effect will be secured in welding and maintained while the metals are cooling from a round bar, as 10, in a plate 11 as shown in Fig- 40 the fusion temperature. ure 5 when the same process is carried out. That It is well known that current applied to parts is to say the real welding union, indicated by the as above explained difiuses itself over outer survertical lines 12, occurs at the bottom of the bar faces of the metallic conductor and concentrates 10 and gradually weakens on the curvature to the for flow between the parts at the points of most horizontal lines 13 where there is again found 45 approximate contact. Accordingly welding, with burnt metal and no adequate welding action.

the usual current, materials and pressure, will More than that it will be evident that the bar 10 commence and be most effective where small areas cannot be completely embedded in the plate 11 as of the parts are brought into approximate contact. the upper portion thereof will have no pressure at But, until my discovery herein disclosed, it has all against the material of the bar 11 and indeed 50 not been known to completely embed one part no contact therewith.

of substantial area wholly within another and In Figures 1 and 2 is shown the process of the still produce a satisfactory weld .at all surfaces present invention. In this case a bar 14 of filled of the connected parts. V-shape in cross section is press-welded into a In the drawing: plate as 15, the lowermost point 14a that contacts 55 Figure 1 is a sectional view showing the rela with the upper edge of the plate 15 being prefer- 2 ably slightly rounded, though it may be sharp. Assuming the plate 15 supported on a welding electrode 16 supplied in the usual manner by a conductor 17 from a suitable source of current and a corresponding electrode 18 constituting the other pole of the circuit and having connected thereto a conductor 19, said electrode 18 is placed upon the bar 14, and put under suitable pressure as indicated by the arrows. It will be seen that as the fusion occurs at the point 14a the surplus soft metal is extruded at the sides and sufficient pressure is maintained to force the bar down into the plate to any depth desired, preferably until its upper flat face is flush with the same. Because of the shape of pressure is progressively maintained at all surfaces of adjacency of the parts as indicated by the vertical lines at 20. when the bar has entered the plate to the desired depth, the current is withdrawn but the pressure is continued to complete the weld, and this weld it will be noted, occurs at all the areas of adjacency or contact of the parts.

The entering slopes of the V, i. e. the angle between the said sides thereof, may be somewhat varied as may best serve the purpose for which the entering part (in this case a bar) is designed to be eflicient and still produce a sufliciently satisfactory weld. The permissible variation also depends somewhat upon the physical characteristics of the metals used. Accordingly, the form of the entering part in sectional area must be determined to some extent in each case by the practitioner of the method, with reference to the conditions mentioned, by actual test. On account of the possible variations of materials and requirements, no definite formula can be given. But I have found, for instance, by test that with medium grade steel an angle of approximately between 60 and degrees is most satisfactory for average variations referable to average purposes. An angle of 80 degrees will result in greater effective pressure parallel to the line of exertion of pressure and a somewhat more satisfactory weld. But such an angle necessarily reduces the depth and thereby in some respects the effective strength of the entering part. An angle of 70 degrees produces a suificient pressure and a weld effective for most purposes with a form of sectional area in the entering part, a bar for instance, desirable for most uses. An angle of 60 the bar a substantially equal degrees will produce a good weld but not so good as with the more obtuse angles above mentioned. With an angle of 50 degrees, the weld begins to show unreliability from a commercial standpoint.

I have described my process of welding applied to a union of a bar and a plate. understood that the principle of my invention may be applied to a like union of other metal structures.

What I claim is:

1. The process of electrical welding, which consists in placing a plate on edge, placing a bar of less depth and of substantially V-shape in cross section against the plate with the apex edge of said V-shaped bar against and across one of the longitudinal edges of the plate, passing a welding current through the bar and plate at their points of intersection, thereby softening the material of the plate that is on edge, applying pressure to the plate and bar, and forcing the V-shaped bar into the longitudinal margin of the plate transversely thereof and continuously exerting outward pressure throughout its depth against the resistance of the longitudinally disposed mass of the plate until the base face of the bar is substantially flush with that edge of the plate initially contacted by the apex edge of said V-shaped bar.

2. The process of electrical welding, which consists in placing a plate on edge, placing against the plate, a bar that is substantially V-shaped in cross section and has its divergent side faces disposed at an angle of between sixty degrees and eighty degrees, said V-shaped bar having its longitudinal apex edge against and across one of the longitudinal edges of the plate, passing a welding current through the bar and plate at their points of intersection, thereby softening the material of the plate that is on edge, applying pressure to the plate and bar, forcing the v-shaped bar into the longitudinal margin of the plate, transversely thereof and continuously exerting outward pressure throughout its depth against the resistance of the longitudinally disposed mass of the plate until the base face of the bar is substantially flush with that edge of the plate initially contacted by the apex edge of said V-shaped bar, cutting oil? the welding current from the plate and bar, and continuing said pressure against the same after the said current has been cut off.

WALTER F. SCHULZ.

But it will be 

